Method of adhering a light reflector unit to a mounting surface



Nov. l, 1966 R. R. GuNDl-:RsoN 3,282,763

METHOD oF ADHERING A LIGHT REFLEGTOR UNIT To A MOUNTING SURFACE Filed March 8, 1962 2 Sheets-Sheet 1 FHI-5.1

ITIE-2 Nov. 1, 1966 R. R. GUNDERSON 3,282,763

METHOD OF ADHERING A LIGHT REFLECTOR UNIT T0 A MOUNTING SURFACE Filed Marsh 8, 1962 2 Sheets-Sheet 2 Fit-f1-5 EXHAUST 24, PRESSURE 4j APPLIED LET 1N AIR PRESSURE United States Patent O 3,282,763 METHOD F ADHERlNG A LIGHT REFLECTOR UNIT T@ A MOUNTING SURFACE Ralph It. IGunderson, 77rd() S. Shore Drive, Chicago, lll. Filed Mar. 8, 1962, Ser. No. 178,400 6 Claims.V (Cl. 156-286) This invention relates to light reflector units provided with adhesive `backings, and to a method for adhering such reflector units to a mounting surface.

Light reflector units are currently widely used in conjunction with highway vehicles. Heretofore, such reflector units have been mounted within metal or plastic brackets which in turn have been ysecured to a vehicle mounting surface by cap screws or other mechanical means. Such inst-allations have failed to provide hermetic seals so that the reflecting and refr-acting surfaces of the reflector units become dirty after use; and in addition, the assembly and attachment of the reflector units has been a time-consuming endeavor.

A rThe present invention provides a particularly effective seal for the interior of the reflector unit, and the method of mounting the reflector unit affords an exceedingly highV resistance to shearing forces tending to loosen and remove the unit from its mounting surface. In addition, the reflector units can be effectively and securely mounted on surfaces of limited area where it would be difficult or impossible to mount reflectors of the prior art.

The primary object of the present invention is to provide a novel reflector unit having a flexible backing peripherally secured thereto andv adapted for adhesively attaching the reflector unit to la mounting surface without the use of brackets or other mechanical accessories.

Another object is to provide a novel method for securing such an adhesive backed reflector unit to a mounting surface.

A further object is to provide a method for securing an adhesive backed reflector unit to a mounting surface in a vacuum so that pressure from a confined quantity of air in an inner cavity of the reflector unit is utilized to force the flexible adhesive backing of the reflector unit into firm and intimate contact with the mounting surface.

Still another object is to provide such a method of adhering reflector units in which pressure within a cavity of the reflector unit operates to firmly adhere a flexible membrane Vto an adhesive backing which is in turn adhered to a mounting surface.

Another object is to provide a reflector unit having an inner -cavity which is closed by a flexible membrane hermetically sealed to the reflector with a two-faced adhesive backing applied to the outer surface of the flexible membrane.

Another object is to provide a novel method for adhering a reflector unit to an uneven or undulating mounting surface in which pressure from Within the reflector is utilized to urge thev flexible adhesive -ba-ck into llrm and intimate contact with the high and low spots of the mounting surface.

A further object is to provide a reflector unit adapted for making secure adhering contact with mounting surfaces having irregular and uneven contour.

The invention is illustrated ina preferred embodiment in the accompanying drawings in which:

F IG. 1 is a top plan view of a light reflector unit;

FIG. 2 is an exploded sectional view of a light reflector unit showing a reflective member, a flexible membrane backing, a two-faced flexible adhesive backing, and a cover for the adhesive backing;

FIG. 3 is a sectional view of the reflector unit of FIG. l showing the reflector and the membrane and adhesive backings in assembled .relation with' central portions of 'the two backings partially adhered to each other;

l 3282,73 v'lateinttetl Nov. 1, 1966 ICC ferred method by which the reflector unit is adhered to a mounting surface;

FlG. 4 being a sectional view of a tool for applying the reflector unit and illustrating the reflector unit ybeing held against a movable plunger Within the evacuated chamber of the tool;

FIG. 5 being a v iew Vsimilar to FIG. 4 illustrating the tool pushed against a mounting surface so that internal pressure within the cavity within the reflector unit pushes outwardly upon the membrane backing and ad-hesive backing of the reflector unit to press the two backings firmly together ,in their central portions and to press t-he central portion of the exposed adhesive backing flrmly against the mounting surface;

FIG. 6 being a view similar to FIG. 5 with the central chamber of the tool still exhausted and showing the application of a force to the movable plunger within the chamber to apply pressure against the peripheral rim of the reflector unit forcing the outer marginal areas of the adhesive backing'against the mounting surface;

FIG. 7 being a View similar to FIG. 6 illustrating the release of the vacuum within the inner chamber of the tool permitting air pressure to rush in to the evacuated chamber and against the exposed face of the reflector unit; and,

FIG. 8, is a sectional side elevational view showing the reflectorV unit of FIG. 7 ladhered to a mounting surface with the membrane backing and adhesive backing intimately secured .to each other in -all opposed portions and with the .adhesive backing firmly adhered to all portions of the mounting surface, whether the portions are concave, convex or flat, A

In the embodiment `illustrated and referring particularly to FIGS. 1 through 3, a light reflector unit, generally designated 2t), is shown. The reflector unit 20 preferably includes an integral reflective member 21 formed from a light-transmitting synthetic plastic. The material lgenerally used is methyl methacrylate :commonly sold under As shown in FIG. 2, a pair of backing members arev preferably provided for securement to the reflective member 21 to conne a volume of air pressure within the cavity 26 of the reflective member 21. The innermost of the two backing members is preferably in the form of an annular flexible membrane or backing 27 which is tightly secured in its peripheral marginal portions to the rim 25 of the reflective member 21. The membrane or backing 27 lmay be formed of a sheet plastic or durable paper material and is preferably provided with an inner reflecting surface 28 of thin aluminum foil or other high reflective material s-o that incident light striking the surface 2S provides brightened or live portions of the reflective member 2l. In the'preferred form the membrane Or backing 27 is heat sealed to the annular lip or rim 25 of the reflective member.

The outermost backing member is preferably in the form of an annular two-faced adhesive backing Sil. The adhesive ybacking of 30 may be `formed of a thin plastic or a durable paper sheet material which is provided with a pressure sensitive adhesive on each of its opposite faces. Its inner face is adhered continuously in an annular pattern to the peripheral portions of the membrane 2'7.

sesame The backings 27 and 30 are preferably not `adhered across the reflective member 2l with drum-like tightness; that is, there is some looseness or slack to permit outward movement -as a result -of pressure Within the cavity 26. As best shown in FIG. 3, the central portions of the opposed faces of the two flexible backings 27 and 3l) may initially be only partially adhered to each other. As will subsequently be explained, the central portions are urged into intimate adhering contact by confined `air pressure within the cavity 26 during -application of the reflector unit to a mounting surface. The outer face of the adhesive backing 3d prior to use is covered by a protective paper material 31 adhered in place by the pressure-sensitive adhesive on the outer face of the backing 30. The adhesive used on the backing 30 has adhering qualities of such a nature as to permit the reflector unit to be firmly adhered to a mounting surface whether that surface be formed of metal, wood, plastic, leather, or the like. Also, the flexibility Iand looseness in the backings 27 and 3f) permit the backings to follow the contour of an irregular or uneven surface so that continuous and firm adhering contact is achieved even when the reflector unit is applied to an undulatory surface.

The unique method of adhering the reflector unit 2f) to a mounting surface 32 is diagramm-atically illustrated in FIGS. 4 through 8.

In FIG. 4 the reflect-or unit 20 is sh-own being held in position by a vacuum applied to the inner chamber of a tool, generally designated 33, used for adhering the reflector unit 26 to a mounting surface 32. The reflector unit 20 has had the protective -cover of paper material 3l re-moved to expose `an outer adhesive face of the twofaced adhesive backing 3f). The mounting surface 32 is illustrated as having a high convex area 34 and a low concave area 35 as well as a generally flat area which conditions are commonly encountered on surfaces to which the reflector units are adhered.

Referring to FIG. 4, the tool 33 may include a vacuum bell or cup-shaped housing 36 which has a resilient peripheral seal 37 protruding from the end of its side wall 3S to make an airtight seal against the mounting surface 32 when placed thereagainst as indicated in FIG. 5. The housing 36 is provided with a bottom wall 40 which may be apertured at 41 to accommodate a vacuum hose 42 secured therein and connected to a source of vacuum indicated generally at 43.

The bottom wall 40 may also be provided with a bushing 44 which makes a substantially airtight sliding fit about a shank 4S. The end of the shank 45 is shown herein as secured to a cup-shaped plunger 46 adapted to make a close sliding fit within the side walls 38. The plunger 46 preferably has an opening 47 which permits air to be pulled within the vacuum bell 36 through the vacuum line 42 when it is desired to evacuate the interior of the housing 36. A number of bleeder lines or passages 48 may be formed in 4an annular lip portion 50 of the plunger 46 for a purpose which will subsequently be made more apparent.

When it is desired to adhere a reflector unit 2f) to a mounting surface 32, the cover 31 of the adhesive backing 30 is removed and the unit 2) is placed within the fopen end of the housing 36, as shown in FIG. 4, so that the annular rim rests upon the annular lip portion 50 of the plunger 36. The reflector 'adhering gun or tool y33 is tipped so that the housing opens upwardly, and the the reflector unit 20 is simply dropped into place with its rim 25 upon the lip portion 50 which functions as a shoulder or stop to position the 4reflector unit 2f) within the tool 33. The housing 36 is shaped to accommodate the particular shape and size of the reflector unit which is to be adhered.

After the reflector unit 2d is dropped into place against lip portion S0, Ia vacuum is applied to exhaust air from the interior of the housing 36 and the plunger 46. The evacuation of the housing 36 will cause the ambient air 4 pressure to which the unit 26 is subjected to hold the reflector unit 20 in firm contact against lip portion 59 (see FIG. 4). This is true even though at this time the small ybleeder lines 48 are open to atmospheric pressure and are permitting air pressure to enter in small quantities into the evacuated chamber Awithin the housing 36.

In FIG. 5, the housing 36 has been pressed against a mounting surface 32 so that the annular seal 37 provides an airtight fit against the surface. As the interior of the housing 36 continues to be exhausted under these conditions, the bleeder lines 48 also provide for evacuationl of the -air pressure from between the adhesive face of the reflector unit 20 and the exhausted face of the mounting surface 32. Because of the great decrease in atmospheric pressure within the housing 36, the vatmospheric pressure within the cavity 26 of the reflector unit 26 causes the flexible membrane backing member 27 and the flexible adhesive backing member 30 to bellow outwardly as at 5l so that the entire central portion of the flexible afhesive backing 30 is urged by the internal air pressure within the cavity 26 of the reflector unit 2f) into firm and intimate adhering contact with the mounting surface 32.

It can be seen that this outward bellowing of the two flexible backings 27 and 30 causes the outer adhesive face of the adhesive backing 30 to Search out and enter into low spots 35 on the mounting surface 31 so that there is a continuous and intimate adhering contact between the mounting surface 32 andthe adhesive backing 39 which contact is assured by the positive outward urge of air pressure acting within the cavity 26. In addition, it will be noted that the flexible membrane backing 27 is also urged to slavishly follow the contour of the mounting surface and to be adhered in all its central portions to the inner face of the two-faced adhesive'backing 30. In the practical application of this method with reflector units 2f) of approximately three inch diameter, the interior of the housing 36 is exhausted almost immediately so that the flexible backings 27 and 3f) are instantly bellowed outwardly against the mounting surface 32.

In FIG. 6 the next step of the preferred method is illustrated. A force is applied to the handle 53 in the direction of the arrow to drive the shank 45 and the plunger 46 downwardly against the annular rim 25. This movement drives the reflector unit 20 downwardly against the mounting surface 32 to adhere the outer annular portion of the exposed adhesive face to the mounting surface 32 so that the entire backing 30 is adhered. It should be noted that the entire adhering operation is being conducted in a vacuum so that no air pressure is trapped between the outer face of the adhesive backing 30 and the mounting surface 32.

Immediately after pushing the plunger 46 against the annular rim 25, as shown in FIG. 6, a vacuum line 42 is opened to the ambient air pressure (FIG. 7). The inrushing air pressure strikes the front face 22 of the reflector unit 2t) to exert an additional force pushing the reflector unit even more firmly against the mounting surface 32. Even though the reflective member 21 may be resiliently deformable, the crown of the front face 22 is not affected because downward deformation of the crown is resiliently opposed by the pressure of the confined air within the cavity 26.

After forcing the reflector unit 20 downwardly with the force of the ambient air pressure (FIG. 7), the reflector gun or tool may be removed for a subsequent operation. The reflector unit 26 as finally adhered to a mounting surface is shown in FIG. 8. Reflector units 2f) of the type herein described which are adhered by the method of this invention have been shown to have a tremendously effective and continuous adherence between the backing member and the mounting surface. Tests have indicated that such lens units adhered by the present method exhibit even greater adhering qualities than do those units described in my accompanying application filed herewith. For example, the lens or reflector units 20 are approximately one and one-half times more resistant to shearing forces and have shown improved characteristics particularly on uneven mounting surfaces.

The foregoing detailed description is given for clearness of understanding only and no unnecessary limitations should be understood therefrom, for some modifications will be obvious to those skilled in the art.

I claim:

1. The method of adhering a light refiector unit having an inner cavity to a mounting surface, comprising the steps of: confining air pressure within the inner cavity by positioning a flexible adhesive backing in hermetically sealed relation across the opening to the inner cavity; positioning the refiector unit so that the fiexible adhesive backing is adjacent the mounting surface; placing an airtight enclosure about the refiector unit; and exhausting air pressure from within the enclosure so as to cause confined air pressure in the inner cavity of the reliector unit to urge the flexible backing into an intimate adhering contact with the contour of the mounting surface.

2. The method of adhering a light reflective member having a rearwardly opening cavity to a mounting surface, comprising the steps of: securing an adhesive backing member to the back side of the refiective member to confine air pressure within a rearwardly opening cavity of the refiective member; positioning the reflective member so that the fiexible backing member is adjacent the mounting surface; placing an airtight enclosure about the refiective member and backing; and exhausting air pressure from Within the enclosure to cause air pressure in the cavity to urge the flexible backing and its exposed adhesive face into an intimate adhering contact with the mounting surface.

3. The method of adhering a light reflector unit having an inner cavity to a mounting surface, comprising the steps of: confining air pressure within the inner cavity by positioning a flexible adhesive backing in hermetically sealed relation across the opening to the inner cavity; positioning the retiector unit so that the exposed adhesive face of the flexible backing is adjacent the mounting surface; exhausting air pressure from about the reflector unit to cause confined air pressure in the inner cavity of the reflector unit to urge the central portion of the adhesive face of the fiexible backing outwardly into con-V tinuous and intimate adhering contact with the mounting surface; and pressing the peripheral portion of the exposed adhesive face into adhering contact with the mounting surface while maintaining an area of decreased pressure about the reflector unit.

4. The method of adhering a light reflector unit having an inner cavity to a mounting surface, comprising the steps of: confining air pressure within the inner cavity by positioning a flexible adhesive backing in hermetically sealed relation across the opening to the inner cavity; positioning the refiector unit so that the exposed adhesive face of the fiexible backing is adjacent the mounting surface; and decreasing air pressure about the reiiector unit and adhesive backing to cause the fiexible backing to deform outwardly into continuous and intimate adhering contact with the mounting surface.

5. The method of adhering to a mounting surface a light refiector unit having an inner cavity and provided with a exible adhesive backing, comprising the steps of: positioning the front face of the reflector unit against stops within a vacuum chamber of a housing so that the ambient air pressure holds the unit against the stops; positioning the housing against a mounting surface to form an air-tight enclosure about the reflector unit so that the chamber is evacuated of air pressure and causes the flexible backing of the refiector unit to be bulged outwardly by confined air pressure within a cavity of the refiector unit into intimate adhering contact with the mounting surface; and forcing the reflector unit against the mounting surface to collapse the outwardly bulged backing and to adhere the peripheral portion of the backing member of the reflector unit to the mounting surface.

6. The method of adhering to a mounting surface a light reflector unit having an inner cavity and provided with a fiexible adhesive backing, comprising the steps of: positioning the front face of the reflector unit against stops within a vacuum chamber of a housing so that the ambient air pressure holds the unit against the stops; positioning the housing against a mounting surface to form an airtight enclosure about the refiector unit so that the chamber is evacuated of air pressure and causes the flexible backing of the reflector unit to be bulged outwardly by confined air pressure within a cavity of the reflector unit into intimate adhering contact with the mounting surface; moving the reflector unit against the mounting surface to collapse the outwardly bulged backing and to adhere the peripheral portion of the backing member of the refiector unit to the mounting surface; and admitting ambient air pressure into the evacuated chamber of the housing and against the face of the reflector unit to force the reflector unit toward the mounting surface.

References Cited by the Examiner Nier 156-306 X EARL M. BERGERT, Primary Examiner.

I. H. PEDERSEN, JACOB STEINBERG, I. J. BURNS, H. ANSI-IER, D. I. HOFFMAN, Assistant Examiners. 

1. THE METHOD OF ADHERING A LIGHT REFLECTOR UNIT HAVING AN INNER CAVITY TO A MOUNTING SURFACE, COMPRISING THE STEPS OF: CONFINING AIR PRESSURE WITHIN THE INNER CAVITY BY POSITIONED A FLEXIBLE ADHESIVE BACKING IN HERMETICALLY SEALED RELATION ACROSS THE OPENING TO THE INNER CAVITY; POSITIONING THE REFLECTOR UNIT SO THAT THE FLEXIBLE ADHESIVE BACKING IS ADJACENT THE MOUNTING SURFACE; PLACING AN AIRTIGHT ENCLOSURE ABOUT THE REFLECTOR UNIT; AND EXHAUSTING AIR PRESSURE FROM WITHIN THE ENCLOSURE SO AS TO CAUSE CONFINED AIR PRESSURE IN THE INNER CAVITY OF THE REFLECTOR UNIT TO URGE THE FLEXIBLE BACKING INTO AN INTIMATE ADHERING CONTACT WITH THE CONTOUR OF THE MOUNTING SURFACE. 